World Grain - August 2018 - 62

FQ

FEED QUARTERLY

Building a mill to make
the products you need
Using a block flow diagram shows how
the processes and steps are connected
by Fred Fairchild

This is the fourth in a series of articles on planning a new
or expanding an existing facility. In the February 2018 issue
of World Grain, we examined factors to be considered when
deciding where to build a new feed mill. In the April 2018 issue, we discussed the mix and amounts of products needed to
be produced by the facility. We determined initial and future
production rates needed to make the amount of feed needed in
HDFKFDVH:HDOVRGHWHUPLQHGWKH¿QDOVKLSSLQJIRUPEXONRU
EDJJHGIRUWKH¿QLVKHGSURGXFWV
In the May 2018 issue, we introduced two generic product
IRUPXODV7KH ¿UVW LV D JHQHULF 6WDUWHU*URZHU %URLOHU IHHG
7KHVHFRQGLVDJHQHULF6ZLQH6WDUWHUSHOOHWHGIHHG8V
ing these formulas, we picked out the location or systems
where each ingredient was located to be added to the mix for a
FRPSOHWHIRUPXOD8VLQJWKHLQJUHGLHQWVIURPWKHVHIRUPXODV
we calculated the amount and type of storage needed for each
ingredient and where that was located.
In this article, we will determine the steps needed to proGXFHWKHUHTXLUHGSURGXFWVDQGGHYHORSDEORFNÀRZRIKRZ
the processes and steps are connected. The products made include mash feed, pelleted feed, textured feed, processed whole
JUDLQVUROOHGSUHPL[HVDQGEXONRUEDJJHGVKLSPHQW8VLQJ
WKLVLQIRUPDWLRQWKHPLOOPXVWEHDEOHWRXVHJULQGLQJÀDNLQJ
(for textured products), batching, mixing, pelleting, texturing
and premixing systems.
(DFKRIWKHVWHSVLQWKHSURFHVVFDQEHGH¿QHGDVDPDQX
facturing step. Once all the required manufacturing steps are
LGHQWL¿HGZHZLOOGUDZD%ORFN)ORZ'LDJUDPVKRZLQJKRZ
the steps are related.

grains, protein meals (soybean meal, etc.), wheat middlings,
distiller's grains, minerals and other large use ingredients that
are received in large size shipments and stored in large bins.
Liquids delivered in large quantities such as fat, molasses or
others are delivered in truck or rail car lots. Large tanks with
temperature control are needed for this storage. Most bulk
ready-to-use ingredients are stored in overhead working bins
above the batching system.
6PDOOHULQJUHGLHQWVVXFKDVPLFURLQJUHGLHQWVDQGSUHPL[HV
are received in bagged form or totes. Even little-used liquids
may be received in liquid totes. All of these ingredients require physical handling and are kept in storage in a warehouse
setting before being used.
Raw Ingredient Pre-Processing: Whole grains and other
ingredients such as alfalfa pellets are normally ground into
small size particles before being sent to the overhead working
bins above the batching system. If textured feeds are made,
WKHZKROHJUDLQLVVWHDPWUHDWHGEHIRUHEHLQJUROOHGRUÀDNHG
for the formulation. Any facility using an ingredient that
needs to be processed before using must be equipped to do the
necessary processing.
Batching: Once all ingredients for the formulation of the
various products are in the proper form, they are placed in
overhead working bins above the batching system. The
amount of each ingredient for a given formula is metered into
the scale hopper and weighed to get the proper amount of each
ingredient for the formula. The micro-ingredients, except for
items to be hand-added to a formula, are individually weighed
up in a micro-system for delivery to the mixer. Once the dry
LQJUHGLHQWV DUH DOO ZHLJKHG XS LQ WKH PDLQ VFDOHV DQGRU
MANUFACTURING STEPS
micro-scale system they are ready to be discharged into the
Receiving: Many different ingredients need to be received to mixer.
PDNHWKHUHTXLUHG¿QLVKHGIHHGSURGXFWV7KLVZRXOGLQFOXGH
Mixing: The ingredients dropped from the main scales are
62

August 2018 / World Grain / www.World-Grain.com


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Table of Contents for the Digital Edition of World Grain - August 2018

http://digital.world-grain.com/sosland/wg/2019_07_01
http://digital.world-grain.com/sosland/wg/2019_06_01
http://digital.world-grain.com/sosland/wg/2019_05_01
http://digital.world-grain.com/sosland/wg/2019_04_01
http://digital.world-grain.com/sosland/wg/2019_03_01
http://digital.world-grain.com/sosland/wg/2019_02_01
http://digital.world-grain.com/sosland/wg/2019_01_01
http://digital.world-grain.com/sosland/wg/2018_12_01
http://digital.world-grain.com/sosland/wg/2018_11_01
http://digital.world-grain.com/sosland/wg/2018_10_01
http://digital.world-grain.com/sosland/wg/2018_09_01
http://digital.world-grain.com/sosland/wg/2018_08_01
http://digital.world-grain.com/sosland/wg/2018_07_01
http://digital.world-grain.com/sosland/wg/2018_06_01
http://digital.world-grain.com/sosland/wg/2018_05_01
http://digital.world-grain.com/sosland/wg/2018_04_01
http://digital.world-grain.com/sosland/wg/2018_03_01
http://www.nxtbook.com/sosland/wg/2018_02_01
http://www.nxtbook.com/sosland/wg/2018_01_01
http://www.nxtbook.com/sosland/wg/2017_12_01
http://www.nxtbook.com/sosland/wg/2017_11_01
http://www.nxtbook.com/sosland/wg/2017_10_01
http://www.nxtbook.com/sosland/wg/2017_09_01
http://www.nxtbook.com/sosland/wg/2017_08_01
http://www.nxtbook.com/sosland/wg/2017_07_01
http://www.nxtbook.com/sosland/wg/2017_06_01
http://www.nxtbook.com/sosland/wg/2017_05_01
http://www.nxtbook.com/sosland/wg/2017_04_01
http://www.nxtbook.com/sosland/wg/2017_03_01
http://www.nxtbook.com/sosland/wg/2017_02_01
http://www.nxtbook.com/sosland/wg/2017_01_01
http://www.nxtbook.com/sosland/wg/2016_12_01
http://www.nxtbook.com/sosland/wg/2016_11_01
http://www.nxtbook.com/sosland/wg/2016_10_01
http://www.nxtbook.com/sosland/wg/2016_09_01
http://www.nxtbook.com/sosland/wg/2016_08_01
http://www.nxtbook.com/sosland/wg/2016_07_01
http://www.nxtbook.com/sosland/wg/2016_06_01
http://www.nxtbook.com/sosland/wg/2016_05_01
http://www.nxtbook.com/sosland/wg/2016_04_01
http://www.nxtbook.com/sosland/wg/2016_03_01
http://www.nxtbook.com/sosland/wg/2016_02_01
http://www.nxtbook.com/sosland/wg/2016_01_01
http://www.nxtbook.com/sosland/wg/2015_12_01
http://www.nxtbook.com/sosland/wg/2015_11_01
http://www.nxtbook.com/sosland/wg/2015_10_01
http://digital.world-grain.com/sosland/wg/2015_09_01
http://digital.world-grain.com/sosland/wg/2015_08_01
http://digital.world-grain.com/sosland/wg/2015_07_01
http://digital.world-grain.com/sosland/wg/2015_06_01
http://digital.world-grain.com/sosland/wg/2015_05_01
http://www.nxtbook.com/sosland/wg/2015_04_01
http://www.nxtbook.com/sosland/wg/2015_03_01
http://www.nxtbook.com/sosland/wg/2015_02_01
http://digital.world-grain.com/sosland/wg/2015_01_01
http://www.nxtbook.com/sosland/wg/2014_12_01
http://www.nxtbook.com/sosland/wg/2014_11_01
http://www.nxtbook.com/sosland/wg/2014_10_01
http://www.nxtbook.com/sosland/wg/2014_09_01
http://www.nxtbook.com/sosland/wg/2014_08_01
http://www.nxtbook.com/sosland/wg/2014_07_01
http://www.nxtbook.com/sosland/wg/2014_06_01
http://www.nxtbook.com/sosland/wg/2014_05_01
http://www.nxtbook.com/sosland/wg/2014_04_01
http://www.nxtbook.com/sosland/wg/2014_03_01
http://www.nxtbook.com/sosland/wg/2014_02_01
http://www.nxtbook.com/sosland/wg/2014_01_01
http://www.nxtbook.com/sosland/wg/2013_12_01
http://www.nxtbook.com/sosland/wg/2013_11_01
http://www.nxtbook.com/sosland/wg/2013_10_01
http://www.nxtbook.com/sosland/wg/2013_09_01
http://www.nxtbook.com/sosland/wg/2013_08_01
http://www.nxtbook.com/sosland/wg/2013_07_01
http://www.nxtbook.com/sosland/wg/2013_06_01
http://www.nxtbook.com/sosland/wg/2013_05_01
http://www.nxtbook.com/sosland/wg/2013_04_01
http://www.nxtbook.com/sosland/wg/2013_03_01
http://www.nxtbook.com/sosland/wg/2013_02_01
http://www.nxtbook.com/sosland/wg/2013_01_01
http://www.nxtbook.com/sosland/wg/2012_12_01
http://www.nxtbook.com/sosland/wg/2012_11_01
http://www.nxtbook.com/sosland/wg/2012_10_01
http://www.nxtbook.com/sosland/wg/2012_09_01
http://www.nxtbook.com/sosland/wg/2012_08_01
http://www.nxtbook.com/sosland/wg/2012_07_01
http://www.nxtbook.com/sosland/wg/2012_06_01
http://www.nxtbook.com/sosland/wg/2012_05_01
http://www.nxtbook.com/sosland/wg/2012_04_01
http://www.nxtbook.com/sosland/wg/2012_03_01
http://www.nxtbook.com/sosland/wg/2012_02_01
http://www.nxtbook.com/sosland/wg/2012_01_01
http://www.nxtbook.com/sosland/wg/2011_12_01
http://www.nxtbook.com/sosland/wg/2011_11_01
http://www.nxtbook.com/sosland/wg/2011_10_01
http://www.nxtbook.com/sosland/wg/20111_09_01
http://www.nxtbook.com/sosland/wg/2011_08_01
http://www.nxtbook.com/sosland/wg/2011_07_01
http://www.nxtbook.com/sosland/wg/2011_06_01
http://www.nxtbook.com/sosland/wg/2011_05_01
http://www.nxtbook.com/sosland/wg/2011_04_01
http://www.nxtbook.com/sosland/wg/2011_03_01
http://digital.world-grain.com/sosland/wg/2011_02_01
http://digital.world-grain.com/sosland/wg/2011_02_01
http://digital.world-grain.com/sosland/wg/2011_01_01
http://digital.world-grain.com/sosland/wg/2010_12_01
http://digital.world-grain.com/sosland/wg/2010_11_01
http://digital.world-grain.com/sosland/wg/2010_10_01
http://digital.world-grain.com/sosland/wg/2010_09_01
http://digital.world-grain.com/sosland/wg/2010_08_01
http://digital.world-grain.com/sosland/wg/2010_07_01
http://digital.world-grain.com/sosland/wg/2010_06_01
http://digital.world-grain.com/sosland/wg/2010_05_01
http://digital.world-grain.com/sosland/wg/2010_04_01
http://digital.world-grain.com/sosland/wg/2010_03_01
http://digital.world-grain.com/sosland/wg/2010_02_01
http://digital.world-grain.com/sosland/wg/2010_01_01
http://digital.world-grain.com/sosland/wg/2009_12_01
http://digital.world-grain.com/sosland/wg/2009_11_01
http://digital.world-grain.com/sosland/wg/2009_10_01
http://digital.world-grain.com/sosland/wg/2009_09_01
http://digital.world-grain.com/sosland/wg/2009_08_01
http://digital.world-grain.com/sosland/wg/2009_07_01
http://digital.world-grain.com/sosland/wg/2009_06_01
http://digital.world-grain.com/sosland/wg/2009_05_01
http://digital.world-grain.com/sosland/wg/2009_04_01
http://digital.world-grain.com/sosland/wg/2009_03_01
http://digital.world-grain.com/sosland/wg/2009_02_01
http://digital.world-grain.com/sosland/wg/2009_01_01
http://digital.world-grain.com/sosland/wg/2008_12_01
http://digital.world-grain.com/sosland/wg/2008_11_01
http://digital.world-grain.com/sosland/wg/2008_10_01
http://digital.world-grain.com/sosland/wg/2008_09_01
http://digital.world-grain.com/sosland/wg/2008_08_01
http://digital.world-grain.com/sosland/wg/2008_07_01
http://digital.world-grain.com/sosland/wg/2008_06_01
http://digital.world-grain.com/sosland/wg/2008_05_01
http://digital.world-grain.com/sosland/wg/2008_04_01
http://digital.world-grain.com/sosland/wg/2008_03_01
http://digital.world-grain.com/sosland/wg/2008_02_01
http://digital.world-grain.com/sosland/wg/2008_01_01
http://digital.world-grain.com/sosland/wg/2007_12_01
http://digital.world-grain.com/sosland/wg/2007_11_01
http://digital.world-grain.com/sosland/wg/2007_10_01
http://digital.world-grain.com/sosland/wg/2007_09_01
http://digital.world-grain.com/sosland/wg/2007_08_01
http://digital.world-grain.com/sosland/wg/2007_07_01
http://digital.world-grain.com/sosland/wg/2007_06_01
http://digital.world-grain.com/sosland/wg/2007_05_01
http://digital.world-grain.com/sosland/wg/2007_04_01
http://digital.world-grain.com/sosland/wg/2007_03_01
http://digital.world-grain.com/sosland/wg/2007_02_01
http://digital.world-grain.com/sosland/wg/2007_01_01
http://digital.world-grain.com/sosland/wg/2006_12_01
http://digital.world-grain.com/sosland/wg/2006_11_01
http://digital.world-grain.com/sosland/wg/2006_10_01
http://digital.world-grain.com/sosland/wg/2006_09_01
http://digital.world-grain.com/sosland/wg/2006_08_01
http://digital.world-grain.com/sosland/wg/2006_07_01
http://digital.world-grain.com/sosland/wg/2006_06_01
http://digital.world-grain.com/sosland/wg/2006_05_01
http://digital.world-grain.com/sosland/wg/2006_04_01
http://digital.world-grain.com/sosland/wg/2006_03_01
http://digital.world-grain.com/sosland/wg/2006_02_01
http://digital.world-grain.com/sosland/wg/2006_01_01
http://digital.world-grain.com/sosland/wg/2005_12_01
http://digital.world-grain.com/sosland/wg/2005_11_01
http://digital.world-grain.com/sosland/wg/2005_10_01
http://digital.world-grain.com/sosland/wg/2005_09_01
http://digital.world-grain.com/sosland/wg/2005_08_01
http://digital.world-grain.com/sosland/wg/2005_07_01
http://digital.world-grain.com/sosland/wg/2005_06_01
http://digital.world-grain.com/sosland/wg/2005_05_01
http://digital.world-grain.com/sosland/wg/2005_04_01
http://digital.world-grain.com/sosland/wg/2005_03_01
http://digital.world-grain.com/sosland/wg/2005_02_01
http://digital.world-grain.com/sosland/wg/2005_01_01
http://digital.world-grain.com/sosland/wg/2004_12_01
http://digital.world-grain.com/sosland/wg/2004_11_01
http://digital.world-grain.com/sosland/wg/2004_10_02
http://digital.world-grain.com/sosland/wg/2004_10_02
http://digital.world-grain.com/sosland/wg/2004_10_01
http://digital.world-grain.com/sosland/wg/2004_09_01
http://digital.world-grain.com/sosland/wg/2004_08_01
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